Situation

Broken Door Flap from either the Control Module
or Expansion Module(s)

Issue

A broken door flap can prevent the picker from properly homing which will cause a no initialization situation.

Inspect floor thoroughly not just for the broken pieces of plastic of the old door flap but also for the small spring.

You can run the library without the flap; but, the robot enters a safe mode that runs all motions at 1/4 speed
anytime the IE station is open.

The door flap should be replaced so the library will operate as designed.

Issue 2.

Possible Cause

The door flap is usually broken by rapid closing of the I/E station.
See image below to see an example of a broken door flap.

Figure 1 - Example of a ML6000 Broken Door Flap

If you open the I/E station and don't see a movable black plastic protective flap;
but, see a silver metal surface on the bottom with two micro-switches that flap is missing.

Take the library offline. This can be done by powering down the library.
Open and remove the I/E slide, if necessary.

There is a small silver roller that must be lifted by reaching through the opening to release the slide.

Once you have the library open perform a thorough search of the inside of the library for all the broken
pieces from the old flap.

If the complete left tab/peg is broken off and the spring is missing, search for that as well.

Note:

If you have confirmed the ML6000 Door Flap is broken, please contact Dell Technical Support for further assistance.

If possible, please take a picture of the broken door flap to help expedite the case and process thereof.

Issue 3.

Resolution

Note:

At this point, if the door flap replacement part has been dispatched, please contact Dell Technical Support for assistance in replacing the door flap.

Especially, if no Onsite Technician was sent with the replacement part.

The following can be done to replace a broken door flap:

Take the library offline. This can be done by powering down the library.

Open and remove the I/E slide, if necessary.

There is a small silver roller that must be lifted by reaching through the opening to release the slide.

Once you have the library open perform a thorough search of the inside of the library for all the broken
pieces from the old flap.
If the complete left tab/peg is broken off and the spring is missing, search for that as well.

To install the new flap, insert right hand peg into the adjacent mounting hole.
Holding the flap in a partially closed position can make installation easier.
Then depress the top left tab while sliding the peg into it's mounting hole.

In the CM (Control Module) and the upper EM (Expansion Module), the spring contacts the roof of the library,
inside/behind the flap.

In the lower EM the spring has a small mounting tab into which the spring must be inserted.

There is also a physical actuator link between the upper and lower EM flaps.

If you find a long slender piece of plastic it is probably the link bar.
Refer to the pictures to see the flaps, the link mechanism and the proper spring mounting.

Make note that the right side of the spring, when viewed from the front,
fits into a notch in the right hand tab in the upper left area of the flap.

Replacement Part, as follows and pictured:

Figure 2 - ML6000 Control Module Door Flap

Figure 3 - ML6000 Expansion Module Door Flap

Figure 4 - ML6000 Lower I/E Door Flap

Quick Tips content is self-published by the Dell Support Professionals who resolve issues daily. In order to achieve a speedy publication, Quick Tips may represent only partial solutions or work-arounds that are still in development or pending further proof of successfully resolving an issue. As such Quick Tips have not been reviewed, validated or approved by Dell and should be used with appropriate caution. Dell shall not be liable for any loss, including but not limited to loss of data, loss of profit or loss of revenue, which customers may incur by following any procedure or advice set out in the Quick Tips.